Removing and installing alternator, 2.0 l SDI engine — VW

🧭 Before you start

Fits: platform code 5M1

• Timing position: the crankshaft or camshaft is set and locked during this job

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• When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Disconnect battery .

📋 Procedure

1. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Disconnect battery .
2. Pull engine cover upwards (arrows A) and forwards (arrow B).
3. Disconnect DF wire connector (1) and pull off protective cap (2).
4. Unscrew B+ (battery positive) wire (arrow) from alternator.
5. Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected.

6. ⚠ Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be destroyed! — Mark direction of rotation of poly V-belt.
7. Release tension of poly V-belt by swivelling tensioning element in direction of (arrow) using a 16 mm open-jaw spanner.
8. Lock tensioning element using locking pin T10060 A.
9. Remove poly V-belt.
10. Remove securing bolts of alternator (arrows).
11. Unscrew wiring retainer (arrow) from alternator.
12. Remove alternator.
13. Drive threaded sleeves (A) about 4 mm in direction of (arrow) out of alternator housing.
14. ⚠ When installing used poly V-belts observe the direction of rotation marked on removal!Before installing poly V-belt, ensure that all assemblies (alternator, air conditioner compressor, vane pump) are installed correctly.When fitting belt, ensure that poly V-belt seats correctly in pulleys! — Tighten threaded connections to specified torques .
15. ⚠ Observe notes for battery terminal clamp bolt . — Reconnect battery .
16. Start engine and check belt is running correctly.
17. Switch off engine.

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